US4808791A - Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation - Google Patents

Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation Download PDF

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Publication number
US4808791A
US4808791A US07/135,307 US13530787A US4808791A US 4808791 A US4808791 A US 4808791A US 13530787 A US13530787 A US 13530787A US 4808791 A US4808791 A US 4808791A
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Prior art keywords
cast iron
laser beam
die
regions
heating
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Expired - Lifetime
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US07/135,307
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English (en)
Inventor
Luciano Puozzo
Guido Contrafatto
Paolo Gay
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Fiat Auto SpA
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Fiat Auto SpA
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Application filed by Fiat Auto SpA filed Critical Fiat Auto SpA
Assigned to FIAT AUTO S.P.A., 10135 TORINO reassignment FIAT AUTO S.P.A., 10135 TORINO ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CONTRAFATTO, GUIDO, GAY, PAOLO, PUOZZO, LUCIANO
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    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00Heat treatments of cast-iron
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08Devices involving relative movement between laser beam and workpiece
    • B23K26/10Devices involving relative movement between laser beam and workpiece using a fixed support, i.e. involving moving the laser beam
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B25HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25JMANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J9/00Program-controlled manipulators
    • B25J9/02Program-controlled manipulators characterised by movement of the arms, e.g. cartesian coordinate type
    • B25J9/023Cartesian coordinate type
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/06Surface hardening
    • C21D1/09Surface hardening by direct application of electrical or wave energy; by particle radiation
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/0068Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S148/00Metal treatment
    • Y10S148/902Metal treatment having portions of differing metallurgical properties or characteristics
    • Y10S148/903Directly treated with high energy electromagnetic waves or particles, e.g. laser, electron beam

Definitions

  • This invention relates to a method for processing large cast iron dies, particularly of the type used in the automobile industry for pressing sheet metal to form vehicle body parts.
  • Such dies are usually constructed at the present time of alloy cast iron, which after casting is mechanically machined, this being followed in most cases by surface hardening of those regions of the die which are subjected to maximum wear when in use.
  • the purpose of the surface hardening is to harden these die regions in order to increase their wear resistance, which is known to depend on the surface hardness, so increasing the life of the entire die and obviating the need to take costly action to restore its initial geometry, with consequent production loss.
  • flame hardening has numerous drawbacks: it is of slow implementtion and cannot be automated due to the fact that because of its nature it cannot be easily parameterized, and therefore has to be executed manually by specialised operators; moreover, whatever the ability of these latter it does not produce uniform results in terms of hardness and depth of hardening, and can give rise to cracks in the die with consequent need for repair; on the other hand, the replacement of flame hardening by other analogous surface hardening treatments such as induction or by treatment with a laser beam has not so far been possible, as the complicated shapes of the dies inevitably result in superimposing of more than one hardening treatment in certain regions of the die, with the consequent formation of cracks.
  • An object of the invention is to provide a method for processing large cast iron dies, in particular those used for vehicle sheet-metal pressing, which obviates the need for flame-hardening while ensuring an acceptable die life; a further object is to provide dies which when in use are able to reduce lubricant consumption and/or reduce or eliminate rejects and machine down-times due to seizure.
  • a method for processing large cast iron dies particularly for sheet-metal pressing for vehicle construction, characterised in that in those die regions which are most subject to wear in relation to the specific use of the die, this latter is subjected to localised heating beyond the austenization temperature by the application of a laser beam which is transferred along said regions by moving it in such a manner that it always remains orthogonal to the surface of said regions so as to rigorously follow their profile; said heating being effected by means of a laser beam focusing head having five capabilities of movement and with such parameters as to produce in correspondence with said die regions a localised martensitic transformation to a depth of at least 1 mm and a surface hardness exceeding 400 HB.
  • the applicant has surprisingly found that by operating in a suitable manner it is possible to apply laser treatment of such an intensity as to produce known surface hardening in cast iron for automobile use in place of the costly, slow and unsatisfactory flame-hardening, without the occurrence, which common opinion has up to the present time considered inevitable, of cracks in those die regions in which more than one successive hardening treatment has been superimposed because of the die geometry.
  • this advantageous method of operation which consists substantially of moving the laser beam focusing head, by which the treatment is carried out, in such a manner that the laser beam always strikes the region to be treated rigorously perpendicular to the surface thereof, ie such that the focusing head movements rigorously follow the profile of the region to be treated however this profile may be, a uniform and considerable increase in the surface hardness of the die is obtained precisely in those regions subject to most wear, with a consequent longer die life than known dies, together with a lower cost and increased speed of treatment.
  • laser hardening is an operation which can be parameterized, it is possible to automate the hardening operation, provided it is carried out by robots able to move the fousing head in the required manner at a rigorously constant distance from the treated surfaces, while at the same time enabling the focusing head to continuously receive the laser beam from the emission source which, in the current state of the art, is known to be of such dimensions and weight for high power emission as to prevent it from undergoing any movement, and is thereore fixed.
  • the laser hardening of such cast irons is implemented according to the invention by a machine numerically controlled along five axes and provided with said focusing head, a laser source and a suitable reflecting mirror system, as will be described hereinafter;
  • the mirrors are of copper construction and are cooled internally by water circulation, and the incident laser beam is made to move over the surface of the region to be treated at constant speed (of the order of 0.3-0.5 m/min) along rectilinear or curved trajectories and in a single predetermined direction along each trajectory, its angle of incidence to the surface of the treated region being always normal to said surface;
  • the laser source used is preferably of the carbon dioxide type and consists of a commercial laser cavity of about 5 kW power, with vacuum gas circulation and arc excitation; preferably, a laser cavity of the "Spectra Physics Model 975" (registered trademark) is used, capable of generating a laser beam of 10.6 micrometers (microns) wavelength, of 44 mm diameter and having a maximum divergence of about
  • the blank holder rings which are usually the components which most suffer the effects of wear during sheet-metal pressing.
  • the reference numeral 1 indicates overall a numerically controlled machine or robot provided with a focusing head 2 for a laser beam 3 produced by a fixed source 4 consisting of any power laser cavity of any known type, not shown in detail for simplicity.
  • the machine 1 which according to the invention is able to set the head 2 with precision at any point in space by offering it five capabilities of movement along five numerically controlled "axes", identified by the arrows and by the letters a, b, c, d and e, comprises a portal structure 5, an arm 6 carried by the structure 4 and projecting perpendicularly therefrom and mobile along a first "axis" or controlled direction a on respective guides 7 carried by an upper cross-member 8 of the structure 5, a carriage 10 carried laterally by and projecting from the arm 5 and mobile thereon on guides 11 along a second "axis" or controlled direction b perpendicular to the axis a, and a shaft or column 12 carried by the carriage 10 and mobile through this latter on suitable mechanisms of any known type, not shown
  • the head 2 is carried angularly rigid by a turret 14 which is mounted rotatable about an axis parallel to the cross-member 8 and is therefore mobile along a fourth "axis" or controlled direction e, in the direction of the arrows.
  • the turret 14 is carried offset from the axis of the shaft 12 in a cantilever manner by a connection piece 15, which is carried angularly rigid by the shaft 12, which besides being able to slide along the direction or axis c is also rotatable about is own axis of symmetry so as to be able to move the connection piece 15 and the turret 14 rigid therewith along a fifth "axis" or controlled direction d.
  • connection piece at is disposed eccentric to the axis of the shaft 12 and cantilevered on the opposite side to the turret (14), and is provided with an aperture 18 through which the beam 3 can enter the connection piece 15 and, by means of a pair of mirrors, not shown but of known type, carried internally by respective oblique faces 20 and 21 of the connection piece 15 and of the turret 14 respectively, be reflected in known manner through these to reach the head 2.
  • the mirrors carried by the walls 20 and 21 are coaxial with the axis of rotation of the turret 14, and a pair of respective mirrors 22 and 23 constructed of copper in known manner and cooled internally by a water flow deviates the beam 3 from the source 4 to the aperture 18.
  • the mirror 22 is carried rigidly by the arm 6 in proximity to the cross-member 8, whereas the mirror 23 projects from the side of the carriage 10. Both the mirrors 22, 23 are disposed obliquely at 45°.
  • the machine 1 is completed by a support table 30 slidable on rails, not shown for simplicity, and on which the dies to be treated (or a part thereof) can be referenced and fixed, and by suitable known electronic control and reference devices, not shown for simplicity, for example consisting of an encoder for each "axis" or controlled direction, a suitable microprocessor unit, and suitable electric motors, preferably of the stepping type, arranged to move the arm 6, the carriage 10, the shaft 12 and the turret 14 in the rectilinear or curved directions a, b, c, d and e in a controlled manner.
  • test-pieces are prepared for each different type of cast iron. All the test-pieces are rectilinear, having dimensions of 40 ⁇ 100 ⁇ 100 mm, and a sectional shape identical to that of the blank holder rings of automobile dies, and are hardened by laser treatment followed by cooling in atmospheric air.
  • a CO 2 laser source is used consisting of a 5 kW "Spectra Physics Model 975" (registered trademark) laser cavity fed with 30 amperes at 3000 volts and kept at 1 Torr, it being coupled to the machine or robot 1 heretofore described.
  • test-pieces are treated with said laser source operating with known equipment, ie by directing the beam onto the regions to be treated using rotary mirrors without taking care to obtain a perpendicular strike, whereas others are treated using the machine 1 in the following manner: after positioning the head 2 over the required region by moving the arm 6 and carriage 10, the beam 3 is orientated perfectly perpendicular to the surface of the region to be treated, by modifying its attitude as the curvature of this region varies so as to rigorously follow its profile.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Mechanical Engineering (AREA)
  • Organic Chemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Thermal Sciences (AREA)
  • Optics & Photonics (AREA)
  • Plasma & Fusion (AREA)
  • Robotics (AREA)
  • Heat Treatment Of Articles (AREA)
  • Laser Beam Processing (AREA)
  • Mounting, Exchange, And Manufacturing Of Dies (AREA)
  • Bending Of Plates, Rods, And Pipes (AREA)
US07/135,307 1986-12-19 1987-12-21 Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation Expired - Lifetime US4808791A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT67947A/86 1986-12-19
IT67947/86A IT1196856B (it) 1986-12-19 1986-12-19 Procedimento di lavorazione di grandi stampi in ghisa particolarmente per lo stampaggio di lamiere di veicoli ed attrezzature per la sua realizzazione

Related Child Applications (1)

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US07/222,744 Division US4851637A (en) 1986-12-19 1988-07-22 Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation

Publications (1)

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US4808791A true US4808791A (en) 1989-02-28

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US07/135,307 Expired - Lifetime US4808791A (en) 1986-12-19 1987-12-21 Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation
US07/222,744 Expired - Lifetime US4851637A (en) 1986-12-19 1988-07-22 Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation

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US07/222,744 Expired - Lifetime US4851637A (en) 1986-12-19 1988-07-22 Method for processing large cast iron dies, particularly for vehicle sheet-metal pressing, and the apparatus for its implementation

Country Status (6)

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US (2) US4808791A (fr)
EP (1) EP0276461B1 (fr)
BR (1) BR8706936A (fr)
DE (1) DE3785745T2 (fr)
ES (1) ES2040238T3 (fr)
IT (1) IT1196856B (fr)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5101089A (en) * 1989-08-01 1992-03-31 Prima Industries S.P.A. Laser machine for cutting and welding
WO1992008568A1 (fr) * 1990-11-15 1992-05-29 Laser Design Inc. Systeme d'alignement et de commande pour laser
US5637243A (en) * 1993-09-27 1997-06-10 Mitsubishi Denki Kabushiki Kaisha Laser cutting machine
US6180917B1 (en) * 1998-03-16 2001-01-30 Prima Industrie S.P.A. Laser beam machine with a cantilever arm
US20080251505A1 (en) * 2007-04-12 2008-10-16 Charles Lee Henderson TrinityCorp RC-1
US8502111B2 (en) 2007-04-12 2013-08-06 Charles L. Henderson Laser woodworking machine
US20170361402A1 (en) * 2014-11-24 2017-12-21 Bystronic Laser Ag Bridge for laser cutting machines
RU2711389C1 (ru) * 2019-05-06 2020-01-17 федеральное государственное бюджетное образовательное учреждение высшего образования "Волгоградский государственный аграрный университет" (ФГБОУ ВО Волгоградский ГАУ) Способ повышения износостойкости рабочих органов из высокопрочного чугуна CO2 - лазером
RU2750673C1 (ru) * 2020-10-27 2021-06-30 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов почвообрабатывающих машин
RU2752724C1 (ru) * 2020-10-27 2021-07-30 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов почвообрабатывающих машин
RU2754332C1 (ru) * 2020-10-27 2021-09-01 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления ресурса рабочих органов почвообрабатывающих машин
RU2754330C1 (ru) * 2020-10-30 2021-09-01 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов глубокорыхлителей
US11471979B2 (en) * 2019-08-16 2022-10-18 Bystronic Laser Ag Machining apparatus for laser machining a workpiece, set of parts for a machining apparatus for laser machining a workpiece and method for laser machining a workpiece using such machining apparatus

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US5061377A (en) * 1989-07-25 1991-10-29 Canadian Liquid Air Ltd./Air Liquide Canada Pipeline reactor and method
US5109148A (en) * 1990-01-26 1992-04-28 Mitsubishi Denki Kabushiki Kaisha Positioning device for a machining apparatus
IT1250211B (it) * 1991-11-22 1995-04-03 Fiat Auto Spa Procedimento per il trattamento superficiale a mezzo laser di metalli da rivestire.
AT401246B (de) * 1992-03-30 1996-07-25 Schuoecker Dieter Dipl Ing Dr Vorrichtung zum bearbeiten eines werkstückes mit einem laserstrahl
EP0780199B1 (fr) * 1995-12-19 2002-03-27 Katayama Steel Rule Die, Inc. Procédé de fabrication d une matrice pour un outil de découpage
US6189414B1 (en) 1995-12-19 2001-02-20 Yoshizawa Industry Inc. Counter plate and cutting die for die cutting machine
US6649862B2 (en) * 2001-07-17 2003-11-18 Tube Tech Machinery S.R.L. Machine for cutting pipes with different cross-sections and diameters by means of a laser beam
US20050103764A1 (en) * 2003-10-01 2005-05-19 Trumpf, Inc. Laser cutting machine with two X-axis drives
US7161114B2 (en) * 2003-10-01 2007-01-09 Trumpf Inc. Laser cutting installation with parts unloading unit
US7045740B2 (en) * 2003-10-01 2006-05-16 Trumpf, Inc. Laser processing installation with integrated loading/unloading of workpieces
US7141758B2 (en) * 2003-10-01 2006-11-28 Trumpf, Inc. Laser processing installation with readily accessible cutting unit
EP2008752B1 (fr) * 2007-06-30 2010-09-22 TRUMPF Werkzeugmaschinen GmbH + Co. KG Machine destinée au traitement de pièces à usiner et procédé destiné au traitement mécanique de pièces à usiner
DE102016211202A1 (de) * 2016-06-22 2017-12-28 Zf Friedrichshafen Ag Verfahren und Vorrichtung zur Verbesserung der Spannungsbelastbarkeit eines druckbeaufschlagbaren Bauteils

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Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5101089A (en) * 1989-08-01 1992-03-31 Prima Industries S.P.A. Laser machine for cutting and welding
WO1992008568A1 (fr) * 1990-11-15 1992-05-29 Laser Design Inc. Systeme d'alignement et de commande pour laser
US5124524A (en) * 1990-11-15 1992-06-23 Laser Design Inc. Laser alignment and control system
US5637243A (en) * 1993-09-27 1997-06-10 Mitsubishi Denki Kabushiki Kaisha Laser cutting machine
US6180917B1 (en) * 1998-03-16 2001-01-30 Prima Industrie S.P.A. Laser beam machine with a cantilever arm
US8502111B2 (en) 2007-04-12 2013-08-06 Charles L. Henderson Laser woodworking machine
US20080251505A1 (en) * 2007-04-12 2008-10-16 Charles Lee Henderson TrinityCorp RC-1
US20170361402A1 (en) * 2014-11-24 2017-12-21 Bystronic Laser Ag Bridge for laser cutting machines
US10661387B2 (en) * 2014-11-24 2020-05-26 Bystronic Laser Ag Bridge for laser cutting machines
RU2711389C1 (ru) * 2019-05-06 2020-01-17 федеральное государственное бюджетное образовательное учреждение высшего образования "Волгоградский государственный аграрный университет" (ФГБОУ ВО Волгоградский ГАУ) Способ повышения износостойкости рабочих органов из высокопрочного чугуна CO2 - лазером
US11471979B2 (en) * 2019-08-16 2022-10-18 Bystronic Laser Ag Machining apparatus for laser machining a workpiece, set of parts for a machining apparatus for laser machining a workpiece and method for laser machining a workpiece using such machining apparatus
RU2750673C1 (ru) * 2020-10-27 2021-06-30 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов почвообрабатывающих машин
RU2752724C1 (ru) * 2020-10-27 2021-07-30 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов почвообрабатывающих машин
RU2754332C1 (ru) * 2020-10-27 2021-09-01 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления ресурса рабочих органов почвообрабатывающих машин
RU2754330C1 (ru) * 2020-10-30 2021-09-01 федеральное государственное автономное образовательное учреждение высшего образования "Российский университет дружбы народов" (РУДН) Способ восстановления рабочих органов глубокорыхлителей

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EP0276461B1 (fr) 1993-05-05
EP0276461A2 (fr) 1988-08-03
EP0276461A3 (en) 1989-03-29
DE3785745D1 (de) 1993-06-09
IT8667947A0 (it) 1986-12-19
US4851637A (en) 1989-07-25
ES2040238T3 (es) 1993-10-16
IT1196856B (it) 1988-11-25
BR8706936A (pt) 1988-07-26
DE3785745T2 (de) 1993-08-19

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